Robotic Beef Carcass Splitting with Vision Detection
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Solution Overview
Problem
Current methods for splitting beef carcasses lack accuracy and efficiency, particularly in identifying the age of the carcass to apply appropriate sanitization procedures and managing the splitting process with robotic systems that can detect tail bone locations and handle saw breakages.
Innovation Solution
A robot-based carcass processing device with a vision-based sensor system and a controller that detects age-indicating indicia on beef carcasses to execute sanitation procedures and automatically moves a band saw to the correct position for splitting, while also detecting saw and support breakages to control the splitting operation, all without needing a support on the opposite side of the carcass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used for splitting beef carcasses, then operational flexibility is maintained, but accuracy and efficiency of carcass splitting deteriorates
Solution Approach 1:
The system uses vision-based sensors to automatically detect tail bone locations and age-indicating indicia on carcasses, eliminating the need for manual identification. The robotic arm autonomously positions and executes splitting operations based on detected features, enabling the system to service itself without continuous human intervention while maintaining high accuracy and efficiency
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system that uses vision-based detection and computer-controlled positioning. The robotic arm with force sensors substitutes human operators, providing consistent precision in locating tail bones and executing splits while improving productivity through automated, repeatable operations
2Manufacturing precision
If robotic systems are used for carcass splitting, then accuracy and efficiency improve, but the ability to detect and respond to saw breakage deteriorates
Solution Approach 1:
The robotic system incorporates force sensors on the robotic arm that continuously monitor resistance during the splitting operation. When the saw encounters abnormal resistance indicating breakage, the sensors provide immediate feedback to the control system, which then stops the operation and alerts operators, ensuring reliable detection while maintaining high splitting accuracy through precise robotic positioning
Solution Approach 2:
The system performs preliminary detection of tail bone locations and age-indicating indicia using vision-based sensors before the splitting operation begins. This advance identification allows the robotic system to plan the exact cutting path and position, ensuring accurate splits while having pre-established parameters for detecting deviations that may indicate saw breakage during execution
3Object-affected harmful factors
If sanitation procedures are executed based on age identification, then food safety compliance improves, but processing time increases
Solution Approach 1:
The vision-based sensor system detects and identifies age-indicating indicia on carcasses as they move along the rail, before the sanitation procedure is executed. This preliminary identification allows the control system to pre-determine the appropriate sanitation protocol, enabling seamless transition to the correct sanitation procedure without manual intervention or time loss for age determination
Solution Approach 2:
The system dynamically adjusts the sanitation procedure based on real-time age identification. Different sanitation protocols are activated according to the detected age category, allowing the system to optimize processing time by applying only the necessary sanitation level for each carcass type rather than using a uniform, time-consuming procedure for all carcasses
4Stability of the object's composition
If a support is placed on the opposite side of the carcass, then stability during splitting improves, but the complexity of the processing system deteriorates
Solution Approach 1:
The carcass is suspended from its own hind legs by hooks on the overhead rail system, using its natural anatomy for support rather than requiring external support structures. This self-supporting arrangement stabilizes the carcass during splitting without adding complex support equipment, as the suspension point naturally positions the tail bone for accurate robotic detection and cutting
Data Source
AI summary
A system for processing a suspended beef carcass as the carcass is moved along a defined path. A robotic arm is carried on a moveable table and has mounted thereon a servo motor-driven band saw capable of effecting a splitting operation on the beef carcass. The band saw is counterbalanced by a mass having a weight less than the weight of the band saw, and the robotic arm has a maximum load-carrying capacity less than the weight of the band saw. A torque monitor for the servo motor detects breaks in the band saw or breaks in the support for the band saw. A vision-based sensor system detects location of a tail bone on the beef carcass and identifies an age-indicating indicia. The system includes a controller in communication with the carcass rail, the carcass processing device and motor, and the vision-based sensor system.